Post-frame building

ABSTRACT

A post frame building that utilizes columns composed of and upper and lower section that is laminated from standard dimensional lumber. The lower section of the columns, made from treated lumber are set into the ground and cut to level. The upper sections, of non-treated lumber is joined to the lower section by means of a staggered slip joint. The upper end of the upper column section forms a sleeve into which a deep heel truss is set. Pre-fabricated girt panels are applied to the columns prior to truss mounting. Prefabricated applied between the trusses form a complete structure.

[0001] This is a continuation of the parent application Ser. No.09/305,175 which was accorded a filing date of May 4, 1999.

CROSS-REFERENCES TO RELATED PROVISIONAL APPLICATIONS

[0002] This invention references, includes the subject matter and claimsthe benefit of previously filed provisional applications, No.60/084,088, filed May 4, 1998; No. 60/100,910 filed Sep. 17, 1998 andNo. 60/101,165 filed Sep. 21, 1998.

BACKGROUND

[0003] 1. Field of Invention

[0004] This invention relates to the construction of buildings andspecifically to those that utilize pre-manufactured components appliedto a modified post-frame type skeleton resulting in an improvedbuilding.

[0005] 2. Developments in the Field

[0006] The demand for strong yet economical buildings for commercial,industrial and agricultural applications has grown over the decades. Inthe agricultural context, barns were usually constructed ofself-supporting heavy timber frames. One alternative to thisconstruction method was the pole barn. This type of building wasconstructed by digging a series of holes around a perimeter of theto-be-constructed building. Long poles, such as wooden telephone orpower poles, were set into the holes. Then numerous horizontal memberscalled “girts” were then nailed to the poles increasing stability andproviding a mechanism for attachment of exterior sheathing. The polesused in this method of construction were merely whole harvested timberwith branches and bark removed. Consequently, the pole varied indiameter being generally wider and the base and narrower at the top. Thepoles, being a natural product were not uniform nor necessarilystraight. This created significant problems in constructing a “square”buildings with true angles. This had further ramifications making thecreation of properly functioning doorways and windows difficult. Sincethe poles narrowed and became less straight at the top, attachment ofthe roof rafters or trusses was difficult and sometimes irregular.

[0007] The use of poles as columns or posts in post and frameconstruction was supplanted by the use of standard dimensional lumber,i.e., 2×4, 2×6 and 2×8 lumber. The regular dimensions allowedconstruction of truer angles. The advent of treated rot resistant lumberallowed the dimensional lumber to be inserted into foundation holes inplace of poles.

[0008] 3. Prior Art

[0009] Of all prior art references, the one that comes the closest tothe to the characteristics of this invention is the building systemdisclosed in U.S. Pat. No. 4,479,342 to Eberle. The Eberle buildingsystem utilizes a columnar structure wherein the lower column sectionsits on a pre-cast or poured concrete footing and is held in place bytamped earth. This could potentially allow wind sheer forces to lift thecolumn from the hole thereby destroying or distorting the structure.Further, the lower section of the Eberle patent discloses a symmetricalslip joint which is inherently weaker than the staggered slip jointsdisclosed in this invention. The upper section of the Eberle column doesnot contain a center member. This requires the unnecessary step ofinserting a leveling block between the upper column members to allow theinsertion of a shallow heel truss. The use of a narrow-heeled truss inthe Eberle patent requires the further utilization of the application ofa knee brace. Utilization of deep heel trusses in this inventioneliminates this particular disadvantage by providing significantstability and wind sheer resistance. Further, the Eberle building methodutilizes either long girts nailed to the exterior of the sidewallcolumns, or girts nailed between and flush with the sidewall columnlips. Utilization of individual girts instead of square and true girtpanels, does not allow the columns to be plumed and leveled when theindividual girts are applied. The present system allows the columns tobe squared using the girt panels. The Eberle building method alsodiscloses individual purlins which are either laid down on top of theupper truss chord or there between. The use of the individual purlins asopposed again, to a prefabricated true and plumed purlin panels does notallow the roof trusses to conform to the square and true purlin panel.Failure to use a centering column requires the user of the Eberleconstruction method to undertake a series of complex measurements andthe use of shims in order to insure the upper ends of the upper columnsections are all level.

OBJECTS AND ADVANTAGES

[0010] In addition to the objects and advantages of the Post-FrameBuilding heretofore described, additional objects and advantages of thepresent invention are as follows:

[0011] (a) to reduce on site labor costs by utilizing pre-manufacturedpurlin and girt panel components. Through the use of jigs and machinery,the pre-manufactured girt and purlin panels are subject to higherquality control, can be manufactured to varying an exactingspecifications and are manufactured with square and true angles.

[0012] (b) to increase safety by reducing the number of componentsneeding to be assembled thereby reducing the need for workers to workatop trusses and other elevated building components.

[0013] (c) Drop in roof purlin panels provide added stability thestructure during truss installation meaning more safety for the workersand less chance of damage to the structure before it is finished fromsevere weather (usually in the form of wind loads associated withthunder storms).

[0014] (d) Purlin panels also help to ensure that the trusses areinstalled straight, plum and at the correct spacing.

[0015] (e) Purlin panels provide a more effective type of bracing forthe top chord (compression chord) compared to roof purlins that are seton top of the truss. This is because the drop-in panels brace more thanjust the top edge of the truss top chord; they brace the depth of thechords by butting into them from both sides. This not only prevents thechords from buckling laterally (out of the plane of the truss), it alsoresists the torsional (twisting) mode of buckling.

[0016] (f) Deep heel trusses provides for added stability to thestructure during construction. Since connection of the post to the heelis more rigid than a normal heel because the bolts or nails can bespread apart and provide a moment connection between the post and truss.In this way, this connection works like a knee brace between the postand truss.

[0017] (g) The moment connection between the post and deep heel trussesstiffens the post-truss frame and reduces lateral building deflectionunder wind loads.

[0018] (h) The moment connection between the post and deep heel trusseschanges the moment distribution in the post and better utilizes thestrength of the post.

[0019] (i) The joining of columns by the use of staggered slip jointsgreatly increases the column's resistance to wind sheer.

[0020] (j) The use of a center column in the upper column sectiongreatly reduces time needed to measure and shim, a disadvantage of theprior art.

[0021] (k) The use of purlin hangers allows the purlin panels to selfposition themselves and allows faster and more accurate attachment toroof trusses.

DETAILED DESCRIPTION OF THE INVENTION

[0022] The preferred embodiment of this method of construction willresult in a post-frame building that will have side walls, end walls anda gabled roof formed from pre-manufactured trusses. The mechanism ofsupport for the side walls, end walls and roof trusses will be aplurality of vertical columns 1, (FIG. 1 ) each set into a hole in theearth 2. Holes 2 are dug or bored into the ground forming the perimeterof the structure. The columns 1 are comprised of an upper column section3 (FIG. 1A) and a lower column section 4 (FIG 1B). The lower columnsection 4 is composed of three pieces of dimensional treated lumber andis approximately 8 feet in length. Depending on the size of the buildingand on the application, the dimensional lumber could consist of 2×4,2×6, 2×8, 2×10, or 2×12 or various combinations thereof. The threepieces of dimensional lumber (FIG. 2) are a center piece 5, a firstouter piece 6 and a second outer piece 7. The center piece 5, usually a2×8 and the first outer piece 6 and the second outer piece 7, usually2×6's, are joined together in a laminated configuration using nails insuch a manner that the lower end 8 and the upper end 9 as well as therear face 10 of the lower column section 4 are flush. In this fashion,laminating the 2×8 center piece 5 and the 2×6 first outer piece 6 andthe second outer piece 7, results in a lip 11 protruding approximately 1and ½ inches from the front face of the lower column section 4. The lipcan vary in protuberance depending on the dimensional lumber used andthe application. Nailing of the lower column section 4, proceeds fromthe lower end 8 toward the upper end 9 stopping approximately 2 ½ feetfrom the upper end 9. The lower end 8 (FIG. 3) of the lower columnsection 4 is then drilled through to accept a length of metal rod 12.Depending upon the application, the lower column section 4 may bedrilled to accept one or more metal rods. The lower end 8 is set intothe hole 2 and concrete 13 is inserted into the bottom of the hole 2.The lower column section 4 is fixed in a plumbed and leveled positionallowing the concrete 13 to set.

[0023] After the concrete 13 (FIG. 4) is set, a transit is then used todetermine a uniform level for the upper end of the column pieces for alllower column sections 4 on the building's perimeter. After cuttingaccording to the transit, the top ends of the center column pieces arenow level. Then approximately 2 feet of the upper end of first outerpiece 6 is cut away from the column. Similarly, approximately 1 foot ofthe second outer piece 7, is cut away. This results in the center piece5 being the longest of the three components of the lower column section4, and results in the first outer piece 6 being the shortest componentand finally second outer piece 7 having an intermediate length. Thecenter column piece extends above the outer column pieces therebyforming a tongue 14. An added result is that the center piece tongues 14are all a uniform length in relation to the cut upper ends of firstouter piece 6 and the second outer piece 7. Lumber may be saved by usingshorter pieces of dimensional lumber for the first outer piece 6 and thesecond outer piece 7 during the initial lamination.

[0024] The upper column section 3 (FIG. 1A) is also composed of threepieces of dimensional lumber that, dependent upon the application, canbe lumber of the same or different dimension as the lower column section4. The central column member 15 of the upper column section 3 ismeasured and cut to length such that if the length of the central columnmember 15 of the upper column section 3 is added to the above groundheight of the center column piece 5 of the lower column section 4, thetruss to ground height is achieved. After the central column member 15has been cut to length, a first side member 16 and a second side member17 are cut. The length of the first side member 16 is calculated byadding the following three distances; the distance a (FIG. 1B) from theupper end of the first side piece 6 of the lower column section 4 to theupper end of the central column piece 5; the distance b (FIG. 1)represented by the length of the center column member 15 of the uppercolumn section 3; and the length c (FIGS. 1 and 5) of the truss heel 18.The length of the truss heel (FIG. 5) is determined by the size andlength of the dimensional lumber used for upper truss member 19, thelower truss member 20, and the vertical heel support member 21.

[0025] The length of the second column member 17 (FIG. 1B) is determinedby adding the distance d (FIG. 1B) from the upper end of the second sidepiece 7 of the lower column section 4 to the upper end of the centralcolumn piece 5; the distance b (FIG. 1) represented by the length of thecenter column member 15 of the upper column section 3; and the length c(FIGS. 1 and 5) of the truss heel 18. The center column member 15, (FIG.1A) the first side member 16 and the second side member 17 are thennailed together in a laminated configuration.

[0026] Similar to the configuration of the lower column section 4, thecenter column member 15, of the upper column section 3, usually a 2×8and the first outer member 16 and the second outer member 17, usually2×6's, are joined together in a laminated configuration using nails, insuch a manner that the rear face of the upper column section 3 is flush.Laminating the 2×8 center column member 15 and the 2×6 first outermember 16 and the second outer member 17, results in a lip protrudingapproximately 1 and ½ inches from the front face of the upper columnsection 3, just as was accomplished with the lower column section 4(FIG. 2).

[0027] The lower end of first column member 16 (FIG. 1A) extends belowthe central column member 15 a distance a′ (FIG. 1A) equal to thedistance a (FIG. 1B) from the upper end of first column piece 6 to thetop of the center column piece 5. The lower end of the second columnmember 17, extends below the central column member 15 a distance d′(FIG. 1A) equal to the distance d (FIG. 1B) from the upper end of firstcolumn piece 7 to the top of the center column piece 5. Thisconfiguration results in the lower end of the upper column section 3forming a staggered slip joint (FIG. 1A) capable of accepting the tongue14 (FIG. 1B) of the lower column section 4 such that the lower ends ofthe central column member 15, (FIG. 1) first column member 16 and secondcolumn member 17 meet the upper ends of the center column piece 5, thefirst column piece 6 and the second column piece 7, respectively. Thetongue 14 of the lower column section 4 is inserted into the slip jointformed by the staggered lamination of the members of the upper columnsection and nailed to join the upper columns section 3 and lower columnsection 4 into a single unit.

[0028] Lamination of the upper column members in this fashion alsoproduces a sleeve (FIG. 1A) on the upper end of the upper column sectionformed by the equidistant extension of the upper ends of first columnmember 16 and second column member 17 beyond the upper end of thecentral column member 15. The upper ends of first column member 16 (FIG.5) and second column member 17 are then cut at an angle matching theangle of the upper truss chord 22 and to a length such that the upperends of first column member 16 and second column member 17 are flushwith the upper truss chord 22. The construction of columns 1 is repeatedaround the perimeter of the building approximately 4 to 10 feet apart,until the required plurality is achieved.

[0029] Column construction for columns on the end walls of the postframe building are identical to those for the side walls except thecolumn 1′ (FIG. 6) is oriented within the structure facing outward toaccept an end gable truss 24. The bottom chord of end gable truss 25rests on lip 11. Columns set in this configuration are repeated on theend walls at four to ten feet intervals, until the required plurality isachieved. Further, lumber may saved and girt panel application may beenhanced by using corner columns, both upper and lower sections,constructed of only a center member and a single offset outer member.

[0030] An added structural component for the end wall column is gablecolumn extension 26. The gable column extension 26 is dimensional lumbercut to varying lengths for each end column in order to make contact withthe upper truss member 19. The gable column extension 26 is then setinto the sleeve formed by the first outer column members 16 and thesecond outer column member 17 that normally accepts the truss heel 18under the side wall column configuration. The longest gable columnextension 26 will correspond to the peak of the end gable truss and theshortest will correspond to the end wall column set closest to the sidewalls.

[0031] The primary component of the side and end walls is aprefabricated girt panel 24 (FIG. 7) which spans the distance betweencolumns (FIG. 8). The prefabricated girt panel 24 (FIG. 7) is formedfrom dimensional lumber when two parallel vertical members 25 are joinedwith an array of horizontal members 26 being configured at right angleto the vertical members. The ends of the horizontal members 26 areabutted to the parallel vertical members 25 and are joined to oneanother by any standard means, with a truss plate 27 being the preferredmethod of attachment. Dimensional lumber of any size may be used toconstruct the girt panel 24, however, 2×4 lumber is standard. The girtpanels 24, are configured with the longer dimension of the lumber i.e.,the 3 and ½ inch width forming the face 28 of the vertical 25 andhorizontal members 26. This results in the depth of the girt panel 24being approximately 1 and ½ inches. The girt panel may be fabricated toany width necessary to span the distance between the columns and may bemanufactured to any height necessary to accommodate the appropriatetruss to ground distance.

[0032] The girt panel 24 (FIG. 8) is then raised and placed in betweenthe columns 1. The vertical members 25 of girt panel 24 are mountedagainst, between and flush with the continuous lip 11 formed from the ofthe conjoined lips of the lower column section 4, upper column section 3and protruding heel 18 of the deep heel truss 23. The vertical girtpanel members 25 are then nailed into the column. This is repeatedbetween columns 1 until each and every column 1 forming the perimeter ofthe building is similarly joined. Girt panels for the end walls (FIG. 6)are manufactured to the length similar to that of the side wall girtpanels less the distance represented by the depth of the heel 18 of thedeep heel truss 23. In this way, the end wall girt panels can be mountedunder and flush with the bottom member of the gable end truss 20 andbetween and flush with the end wall columns lips 11.

[0033] After girt panel application a deep heel truss 23 (FIG. 5) isthen inserted into the sleeve formed from first outer column member 16and second outer column member 17. The deep heel truss 23 is constructedto length such that it extends approximately 1 and ½ inches beyond thesleeve formed by first outer member 16 and first outer member 17. Thisextension is designed to rest on and be a continuation of the lip 11.The deep heel truss 23 is secured within the sleeve by nails beingdriven through the first outer member 16 and second outer member 17 intothe heel 18 of the deep held truss 23. This process is continued withopposing side wall trusses accepting opposing ends of the same truss,until all side wall columns and around the perimeter have acceptedtrusses.

[0034] A primary component of the roof is a prefabricated purlin panel29 (FIG. 9). The prefabricated purlin panel 29 is formed when twoparallel vertical members 30 are joined with an array of horizontalmembers 31 being configured at right angle to the vertical members. Theends of the horizontal members 31 are abutted to the parallel verticalmembers 30 and are joined to one another by any standard means with atruss plate 32 being the preferred method of attachment. Dimensionallumber of any size may be used to construct the purlin panel 29,however, 2×4 lumber is standard. The purlin panels 29, are configuredwith the shorter dimension of the lumber i.e., the 1 and ½ inch widthforming the face 33 of the vertical 30 and horizontal members 31. Thisresults in the depth of the purlin panel 29 being approximately 3 and ½inches. The purlin panel 29 (FIG. 10) is then lifted above the trussesand lowered into position between the deep heel trusses 23 and flushwith the top chord of the truss 22 and then nails are driven through thevertical members 30 into the upper truss member 19 of the deep heeltruss 23.

[0035] The purlin panel 29 may either be suspended and manually held inplace while being nailed to the upper truss member 19 or it may besuspended by means of a purlin hanger 34 (FIG. 11). The purlin hanger 34is of metal or other suitable material and is placed on the upper memberof a truss 19 and in a corresponding position on an adjacent truss thepurlin panel is being lowered between. The purlin hanger 34 and iscomposed of a vertical segment 35 for attachment to the upper trussmember 19, a horizontal segment 36 upon which the narrow face 33 of thevertical purlin member 30 rests. The final segment of the purlin hanger34 is the purlin panel receptacle face 37 (FIGS. 11 and 11B). When apurlin panel 29 is lifted above the truss line and lowered in placebetween the upper truss members 19 the vertical purlin member 30 (FIG.12) makes contact with the purlin panel receptacle face 37. As thevertical purlin member 30 along with the entire purlin panel 29continues to be lowered the angular nature of the purlin panelreceptacle face 37 forces the upper truss member 19 into alignment withthe vertical purlin panel member 30 which as it slides down the purlinpanel receptacle face 37 finally resting on the horizontal segment 36 ofthe purling hanger 34. At this point, the upper face 41 (FIG. 11B) ofthe vertical purlin member 30 will be flush with the upper chord 22 ofthe upper truss member 19. A similar mechanism simultaneously positionsthe opposing vertical purlin member against the adjacent truss thepurlin panel is being placed between. Purlin hangers may be used in thenecessary plurality on adjacent trusses to properly support and positiona purlin panel. Alternative embodiments (FIGS. 13 and 13A) wherein thepurlin hanger is suspended form the top chord of the upper truss member19 are illustrated. Here the vertical purlin segment 40 now appearsabove the horizontal purlin segment and is wrapped up and over the upperchord of the upper truss member 19. The vertical purlin segment 40 mayeither be secured or hang from the upper truss member.

[0036] Ceiling panels also containing vertical and horizontal membersare constructed. The panels are then placed between the trusses andflush with the top chord of the truss. Columns as well as girt, purlin,ceiling panels can also be constructed of dimensional steel componentswith standard metal joinery and would be an appropriate choice dependingon the application.

[0037] After the columns are set and constructed, the girt panels areattached thereto. The deep heel trusses are mounted onto the columns andthe purlin panels are then applied to and the upper truss members. Asuitable sheathing, such as metal, for the side an end walls in thenapplied as well as a suitable roofing material. Modifications in thegirt panels such as the addition of headers and lintels will allow doorsand windows essentially completing the structure.

What is claimed is:
 1. A method of constructing a post frame building,said method comprising: setting a series of lower column sections intothe ground in an upright position, each lower section being configuredto mate at its upper end with an upper column section to form a column,each upper column section having a bearing surface at its upper end andthe distance between the bearing surfaces and the lower ends of all ofthe upper column section being equal.
 2. A method of constructing a postframe building wherein the upper section for each column is a laminatedstructure comprising at least three pieces of lumber joined together andthe interior piece in the laminated structure is shorter than the piecesto the side of it, so that its end is offset downwardly from the ends ofthe piece to the side of it, whereby an upwardly opening pocket iscreated in the upper end of the upper section, the bearing surface ofthe upper section being the offset end of the interior piece.
 3. Amethod of constructing a post frame building wherein cutting off sidepieces of the upper section substantially flush with the upper surfaceof the roof structure after the roof structure is installed on thecolumns